Defender 300Tdi (1996+). Manual — part 86
76
CHASSIS AND BODY
28
REPAIR
TAIL DOOR TRIM CASING
Service repair no - 76.34.09
Remove
1. Unscrew 2 bolts and remove grab handle from
rear door.
2. Remove 2 screws and detach wiper motor cover.
3. Remove 7 screws securing trim casing to door.
4. Remove 2 screws and lift wiper motor harness
cover from harness support bracket.
5. Carefully release 8 clips securing trim casing to
door.
6. Remove trim casing and collect door lock cover.
Refit
7. Position door lock cover, fit trim casing and
secure with clips.
8. Fit harness cover and secure with two screws.
9. Secure door panel with retaining screws.
10. Position wiper motor cover and secure with 2
screws.
11. Position grab handle and secure with 2 bolts.
TAIL DOOR LOCK
Service repair no - 76.37.16
Remove
1. Remove door casing
See Tail door trim
casing .
2. Remove screws, washers and nut retainer plate
securing top of lock to door.
3. Remove nuts, washers and stud retainer plate
securing bottom of lock to door.
4. Withdraw lock assembly.
5. Remove door lock gasket.
6. Clean sealant from retainer plates.
7. Insert key into barrel.
8. Depress lock barrel plunger and withdraw barrel
from lock.
Refit
9. Fit new barrel into lock.
10. Apply sealant to lock retainer plates.
11. Fit lock to door with a new gasket.
12. Secure with retainer plates, screws, washers
and nuts.
13. Close door and check for correct latching with
striker. Adjust striker as necessary
See Tail
door striker - adjust .
14. Fit door casing
See Tail door trim casing .
CHASSIS AND BODY
29
REPAIR
TAIL DOOR STRIKER - ADJUST
Service repair no - 76.37.25
Adjust
1. Loosen striker securing screws.
2. Adjust striker and retighten screws.
3. Close door and check for correct latching with
door lock.
4. Carry out further adjustment as necessary. If full
adjustment cannot be achieved carry out
following:
5. Remove striker and nut plate.
6. Elongate holes in body metal which is
sandwiched between striker and nut plate.
7. Refit striker and adjust as necessary.
76
CHASSIS AND BODY
30
REPAIR
SUN ROOF
Service repair no - 76.83.01
Remove
1. Open sun roof fully.
2. Disengage spring lock from operating handle
catch.
3. Holding sun roof at both sides, release hinges
from locating brackets at front of outer frame.
4. Remove sun roof.
5. Starting from centre rear, peel headlining finisher
from inner frame.
6. Remove 18 screws securing inner frame to outer
frame and detach inner frame.
7. Lift outer frame from roof.
NOTE: Assistance may be required to
remove the sun roof assembly.
Refit
8. Clean roof area around outer frame seating.
9. Position outer frame on roof.
10. Fit inner frame to headlining and secure to outer
frame with 18 screws but do not fully tighten.
11. Check alignment of inner and outer frames with
roof mounting and headlining, adjust as
necessary, and fully tighten fixing screws to
10
Nm (7 lbf/ft).
12. Starting from centre rear, fit headlining finisher
lip into locating channel of inner frame.
13. Press finisher firmly over inner frame and
continue around complete frame, ensuring
finisher lies flat on headlining.
14. Fit sun roof hinges fully into locating brackets on
outer frame, and lower the glass panel.
15. Engage operating handle catch with spring lock
of outer frame and close sunroof.
CHASSIS AND BODY
31
REPAIR
INTERIOR MIRROR
Service repair no - 76.10.51
Remove
1. Prise interior mirror arm from mounting plate.
2. Remove 3 screws and remove mounting plate
from headlining.
Refit
3. Fit mounting plate to headlining.
4. Locate lower lug of mirror arm in mounting plate
aperture.
5. Press mirror arm firmly to engage spring clip in
mounting plate aperture.
SUN VISORS
Service repair no - 76.10.47
Remove
1. Raise sun visor.
2. Remove 2 screws and collect sun visor.
Refit
3. Position sun visor and secure with 2 screws.
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